U.S. patent number 9,083,197 [Application Number 13/349,292] was granted by the patent office on 2015-07-14 for dc power supply apparatus.
This patent grant is currently assigned to DENSO CORPORATION, NIPPON SOKEN, INC.. The grantee listed for this patent is Fumio Asakura, Kenji Ochi, Hiroshi Yoshida. Invention is credited to Fumio Asakura, Kenji Ochi, Hiroshi Yoshida.
United States Patent |
9,083,197 |
Asakura , et al. |
July 14, 2015 |
DC power supply apparatus
Abstract
A DC power supply apparatus includes a charging circuit, which
charges a secondary battery of a vehicle from an AC power source
device or a DC power source device. The charging circuit includes a
non-insulating converter circuit and an insulating converter
circuit. A breaker relay disconnects the AC power source device and
the charging circuit in an initial charging period to supply a
large charging current to the secondary battery by the
non-insulating converter circuit. As a result, charging can be
performed with high efficiency without the insulation transformer.
The breaker relay connects the AC power source device and the
charging circuit after the initial charging period. Only the
insulating converter circuit supplies the charging current to the
secondary battery. Thus, adverse effect of stray capacitance of a
circuit of the vehicle can be eliminated.
Inventors: |
Asakura; Fumio (Okazaki,
JP), Ochi; Kenji (Nishio, JP), Yoshida;
Hiroshi (Chiryu, JP) |
Applicant: |
Name |
City |
State |
Country |
Type |
Asakura; Fumio
Ochi; Kenji
Yoshida; Hiroshi |
Okazaki
Nishio
Chiryu |
N/A
N/A
N/A |
JP
JP
JP |
|
|
Assignee: |
NIPPON SOKEN, INC. (Nishio,
JP)
DENSO CORPORATION (Kariya, JP)
|
Family
ID: |
46490298 |
Appl.
No.: |
13/349,292 |
Filed: |
January 12, 2012 |
Prior Publication Data
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|
|
|
Document
Identifier |
Publication Date |
|
US 20120181990 A1 |
Jul 19, 2012 |
|
Foreign Application Priority Data
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|
|
|
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Jan 19, 2011 [JP] |
|
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2011-9082 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B60L
53/53 (20190201); H02J 5/00 (20130101); B60L
53/20 (20190201); H02J 7/02 (20130101); H02J
1/102 (20130101); B60L 53/30 (20190201); B60L
53/11 (20190201); Y02T 10/92 (20130101); Y02T
10/70 (20130101); Y02T 90/14 (20130101); H02M
3/28 (20130101); Y02T 90/12 (20130101); Y02T
10/7072 (20130101) |
Current International
Class: |
H02J
7/00 (20060101); H02J 7/02 (20060101); B60L
11/18 (20060101); H02J 1/10 (20060101); H02M
3/28 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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A-5-276674 |
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Oct 1993 |
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JP |
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A-7-115732 |
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May 1995 |
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JP |
|
A-07-298513 |
|
Nov 1995 |
|
JP |
|
A-2008-312382 |
|
Dec 2008 |
|
JP |
|
A-2009-033800 |
|
Feb 2009 |
|
JP |
|
A-2010-041819 |
|
Feb 2010 |
|
JP |
|
A-2010-178544 |
|
Aug 2010 |
|
JP |
|
B2-4527616 |
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Aug 2010 |
|
JP |
|
Other References
Nov. 27, 2012 Office Action issued in Japanese Patent Application
No. 2011-009082 (with translation). cited by applicant.
|
Primary Examiner: Dunn; Drew A
Assistant Examiner: Chung; Steve T
Attorney, Agent or Firm: Oliff PLC
Claims
What is claimed is:
1. A DC power supply apparatus for converting power supplied from a
power source device including a commercial power line system and
supplying DC power to a load device, the DC power supply apparatus
comprising: a conversion circuit configured to supply the DC power
and including an insulating transformer, the conversion circuit
being switchable to operate as a non-insulating converter circuit,
in which an input and an output is not insulated by the insulating
transformer, or as an insulating converter circuit, in which the
input and the output are insulated by the insulating transformer;
and a breaker device for shutting off power supply from the
commercial power line system to the non-insulating converter
circuit, when the conversion circuit supplies the DC power by the
non-insulating converter circuit.
2. The DC power supply apparatus according to claim 1, wherein: the
breaker device shuts off the power supply from the commercial power
line system to the non-insulating converter circuit and allows the
power supply only from the power source device other than the
commercial power line system to the non-insulating converter
circuit, when the conversion circuit supplies the DC power by the
non-insulating converter circuit; and the breaker device allows the
power supply from the commercial power line system to the
insulating converter circuit and allows only the insulating
converter circuit to convert the power supplied from the commercial
power line system, when the conversion circuit supplies the DC
power by the insulating converter circuit.
3. The DC power supply apparatus according to claim 2, wherein: the
conversion circuit supplies the DC power by the non-insulating
converter circuit, when a predetermined condition is satisfied; and
the conversion circuit supplies the DC power by only the insulating
converter circuit, when the predetermined condition is not
satisfied.
4. The DC power supply apparatus according to claim 3, wherein: the
conversion circuit is a charging circuit for charging the DC power
to a secondary battery provided as the load device; the
predetermined condition is set based on a charging period for the
secondary battery; and the conversion circuit supplies the DC power
by the non-insulating converter circuit in a former period of a
charging period for the secondary battery, and supplies the DC
power by the insulating converter circuit in a latter period of the
charging period for the secondary battery.
5. The DC power supply apparatus according to claim 3, wherein: the
predetermined condition is set based on a magnitude of power supply
capability of the power source device other than the commercial
power line system; the conversion circuit supplies the DC power by
the non-insulating converter circuit when the power supply
capability is higher than a predetermined threshold value, and
supplies the DC power by the insulating converter circuit when the
power supply capability is lower than the predetermined threshold
value.
6. The DC power supply apparatus according to claim 2, wherein: the
conversion circuit includes the non-insulating converter circuit,
the insulating converter circuit and a switching device for
selectively connecting either one of the non-insulating converter
circuit and the insulating converter circuit to the load
device.
7. The DC power supply apparatus according to claim 6, wherein: the
switching device connects the non-insulating converter circuit and
the insulating converter circuit to plural load devices
exchangeably.
8. The DC power supply apparatus according to claim 2, wherein the
conversion circuit includes: a first full-bridge circuit provided
at a primary side of the insulating transformer; a second
full-bridge circuit provided at a secondary side of the insulating
transformer; a switching device for connecting or disconnecting a
primary terminal and a secondary terminal of the insulating
transformer, and connecting and disconnecting a negative line of
the first full-bridge circuit and a negative line of the second
full-bridge circuit; and a switchable converter circuit switchable
to the non-insulating converter circuit or the insulating converter
circuit by the switching device.
9. The DC power supply apparatus according to claim 8, wherein: the
non-insulating converter circuit is a step-up/down converter
circuit, which is formed of an inductive component of the
insulating transformer provided in a connected state of the
switching device, the first full-bridge circuit and the second
full-bridge circuit.
10. The DC power supply apparatus according to claim 1, wherein:
the conversion circuit supplies the DC power by the non-insulating
converter circuit, when a predetermined condition is satisfied; and
the conversion circuit supplies the DC power by only the insulating
converter circuit, when the predetermined condition is not
satisfied.
11. The DC power supply apparatus according to claim 10, wherein:
the conversion circuit is a charging circuit for charging the DC
power to a secondary battery provided as the load device; the
predetermined condition is set based on a charging period for the
secondary battery; and the conversion circuit supplies the DC power
by the non-insulating converter circuit in a former period of a
charging period for the secondary battery, and supplies the DC
power by the insulating converter circuit in a latter period of the
charging period for the secondary battery.
12. The DC power supply apparatus according to claim 10, wherein:
the predetermined condition is set based on a magnitude of power
supply capability of the power source device other than the
commercial power line system; the conversion circuit supplies the
DC power by the non-insulating converter circuit when the power
supply capability is higher than a predetermined threshold value,
and supplies the DC power by the insulating converter circuit when
the power supply capability is lower than the predetermined
threshold value.
13. The DC power supply apparatus according to claim 10, wherein:
the conversion circuit includes the non-insulating converter
circuit, the insulating converter circuit and a switching device
for selectively connecting either one of the non-insulating
converter circuit and the insulating converter circuit to the load
device.
14. The DC power supply apparatus according to claim 10, wherein
the conversion circuit includes: a first full-bridge circuit
provided at a primary side of the insulating transformer; a second
full-bridge circuit provided at a secondary side of the insulating
transformer; a switching device for connecting or disconnecting a
primary terminal and a secondary terminal of the insulating
transformer, and connecting and disconnecting a negative line of
the first full-bridge circuit and a negative line of the second
full-bridge circuit; and a switchable converter circuit switchable
to the non-insulating converter circuit or the insulating converter
circuit by the switching device.
15. The DC power supply apparatus according to claim 1, wherein:
the conversion circuit includes the non-insulating converter
circuit, the insulating converter circuit and a switching device
for selectively connecting either one of the non-insulating
converter circuit and the insulating converter circuit to the load
device.
16. The DC power supply apparatus according to claim 15, wherein:
the switching device connects the non-insulating converter circuit
and the insulating converter circuit to plural load devices
exchangeably.
17. The DC power supply apparatus according to claim 1, wherein the
conversion circuit includes: a first full-bridge circuit provided
at a primary side of the insulating transformer; a second
full-bridge circuit provided at a secondary side of the insulating
transformer; a switching device for connecting or disconnecting a
primary terminal and a secondary terminal of the insulating
transformer, and connecting and disconnecting a negative line of
the first full-bridge circuit and a negative line of the second
full-bridge circuit; and a switchable converter circuit switchable
to the non-insulating converter circuit or the insulating converter
circuit by the switching device.
18. The DC power supply apparatus according to claim 17, wherein:
the non-insulating converter circuit is a step-up/down converter
circuit, which is formed of an inductive component of the
insulating transformer provided in a connected state of the
switching device, the first full-bridge circuit and the second
full-bridge circuit.
19. A DC power supply method for supplying a secondary battery of a
vehicle with DC power to charge the secondary battery by a
conversion circuit, which includes an insulating transformer for
insulating primary side and a secondary side thereof and converts
power of a DC power source device and a commercial AC power source
device, the DC power supply method comprising: checking whether the
secondary battery is to be charged; setting the conversion circuit
to operate as a non-insulating converter circuit, in which the
insulating transformer is inoperative, when the secondary battery
is determined to be charged; disconnecting the non-insulating
converter circuit and the AC power source device from each other,
when the conversion circuit is set to operate as the non-insulating
converter circuit, charging the secondary battery initially by
using only the DC power of the DC power source device by only the
non-insulating converter circuit of the conversion circuit;
checking whether a predetermined switch-over condition is
satisfied, the predetermined switch-over condition indicating that
the secondary battery has been charged initially; setting the
conversion circuit to operate as an insulating converter circuit,
in which the insulating transformer is operative, after the
predetermined switch-over condition is satisfied; connecting the
insulating converter circuit and the AC power source device, when
the conversion circuit is set to operate as the insulating
converter circuit; and charging the secondary battery by using only
the insulating converter circuit of the conversion circuit.
20. The DC power supply method according to claim 19, further
comprising: connecting a primary terminal and a secondary terminal
of the insulating transformer in a period of initial charging of
the secondary battery so that the conversion circuit operates as
the non-insulating converter circuit; and disconnecting the primary
terminal and the secondary terminal of the insulating transformer
after the period of initial charging so that the conversion circuit
operates as the insulating converter circuit.
Description
CROSS REFERENCE TO RELATED APPLICATION
This application is based on and incorporates herein by reference
Japanese patent application No. 2011-9082 filed on Jan. 19,
2011.
TECHNICAL FIELD
The present invention relates to a DC power supply apparatus, which
supplies DC power and may be used, for example, in a charging
system for charging a secondary battery.
BACKGROUND ART
The following patent documents disclose an insulation type DC power
conversion circuit (referred to as an insulation type DC/DC
converter or an insulating converter), the primary side and the
secondary side of which are insulated by an insulating transformer.
The insulating converter is effective to suppress ground leakage of
current.
Patent document 1: JP H07-298513A
Patent document 2: JP 2008-312382A
Patent document 3: JP 2009-33800A (US 2009/0034300A1)
Patent document 4: JP 4527616
In a battery charging system, in which a DC power supply apparatus
may be used, a secondary battery may be charged from a power supply
source such as a commercial power source. In case that the
secondary battery is mounted in a mobile vehicle such as a
four-wheel car, a motorcycle, a ship and an airplane, a circuit
mounted in the mobile vehicle sometimes has a large stray
capacitance. For example, in a case that a secondary battery is
mounted in a vehicle such as a plug-in hybrid car, a capacitance
between a high-voltage circuit mounted in the car and a chassis of
the car is large. The capacitance includes a capacitance of a
filter circuit and stray capacitances of other circuits. The power
supplied from the commercial power line system may leak to the
ground through the stray capacitances. If leakage of current
increases, a ground-fault breaker provided between the commercial
power line system and the DC power supply apparatus will operate to
shut off the power supply. An insulating converter, which uses a
switching circuit and an insulating transformer, is effective to
prevent ground leakage of current. The switching circuit and the
insulating converter however lowers efficiency of power
conversion.
SUMMARY
It is therefore an object to provide a DC power supply apparatus,
which has an improved high power conversion efficiency.
It is another object to provide a DC power supply apparatus, which
exhibits not only an improved power conversion efficiency but also
ground leakage suppression function provided by an insulating
converter.
It is a further object to provide a DC power supply apparatus,
which exhibits a ground leakage suppression function in case of
receiving power from a commercial power line system and realizes a
high efficiency in case of receiving power from a secondary
battery.
A DC power supply apparatus is provided for converting power
supplied from a power source device including a commercial power
line system and supplying DC power to a load device. The DC power
supply apparatus has a conversion circuit and a breaker device. The
conversion circuit is configured to supply the DC power and
includes an insulating transformer. The conversion circuit is
switchable to operate as a non-insulating converter circuit, in
which an input and an output is not insulated by the insulating
transformer, or as an insulating converter circuit, in which the
input and the output are insulated by the insulating transformer.
The breaker device is configured to shut off power supply from the
commercial power line system to the non-insulating converter
circuit, when the conversion circuit supplies the DC power by the
non-insulating converter circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of a DC power
supply apparatus becomes more apparent from the following detailed
description made with reference to the accompanying drawings. In
the drawings:
FIG. 1 is a block diagram of a charging system including a DC power
supply apparatus according to a first embodiment;
FIG. 2 is a circuit diagram of an AC/DC conversion circuit in the
first embodiment;
FIG. 3 is a circuit diagram of a non-insulation type DC power
conversion circuit in the first embodiment;
FIG. 4 is a circuit diagram of an insulation type DC power
conversion circuit in the first embodiment;
FIG. 5 is a flowchart showing an operation performed by a control
circuit in the first embodiment;
FIG. 6 is a graph showing a voltage of a stationary secondary
battery in the first embodiment;
FIG. 7 is a graph showing a charging current in the first
embodiment;
FIG. 8 is a graph showing a switching state of a charging circuit
in the first embodiment;
FIG. 9 is a block diagram of a charging system including a DC power
supply apparatus according to a second embodiment;
FIG. 10 is a block diagram of a charging system including a DC
power supply apparatus according to a third embodiment;
FIG. 11 is a circuit diagram of a switching type DC power
conversion circuit in the third embodiment;
FIG. 12 is a flowchart showing an operation performed by a control
circuit in the third embodiment; and
FIG. 13 is a circuit diagram of a switching type DC power
conversion circuit in a fourth embodiment.
DETAILED DESCRIPTION OF EMBODIMENT
A DC power supply apparatus will be described below in detail with
reference to plural embodiments shown in the drawings. In each
embodiment, same or similar reference numerals are used for same or
similar parts among the plural embodiments thereby to omit the same
description.
First Embodiment
Referring to FIG. 1, a charging system 1 includes a DC power supply
apparatus according to a first embodiment. The charging system 1
includes one or plural power source devices 2, one or plural load
devices 3 and a charging circuit 4, which is a conversion circuit
for converting power supplied from each power source device 2.
Power supplied from the power source device 2 is converted to DC
power of a predetermined voltage by the charging circuit 4 and
supplied to the load device 3. The charging system 1 may be formed
for a house, a housing complex or a charging station, which is
provided for charging an unspecified number of load devices.
Each power source device 2 supplies power of a predetermined power
source voltage. The power source device 2 may be a DC power source
for supplying DC power or an AC power source for supplying AC
power. The DC power source includes a solar power generator 21 and
a stationary type secondary battery 22. The AC power source
includes a commercial power source, which is an AC commercial power
line system 23. The solar power generator 21 includes a
semiconductor solar battery panel mounted on a roof of a house or a
building, for example. The voltage generated by the solar power
generator 21 varies with the amount of solar radiation. The
stationary secondary battery 22 is fixedly provided as a main
secondary battery for the charging system 1. The secondary battery
22 is a battery fixedly provided in a house. The secondary battery
22 is fixedly connected to the charging circuit 4. The secondary
battery 22 may be referred to a first secondary battery. The
secondary battery 22 is chargeable by power supplied from other
power source devices 2 or a secondary battery 31 of the load device
3. For example, the secondary battery 22 is charged by power
supplied from the solar power generator 21 or power supplied from
the commercial power line system 23. The secondary battery 22 may
also be included in the load device 3. The commercial power line
system 23 is a power transmission network provided by a power
supplier such as an electric power company. The commercial power
line system 23 is a single-phase three-line power source and has a
neutral line (0) and voltage lines (U, V). The power source device
2 may further include small-sized power generation equipment such
as a fuel cell or a wind power generator.
The load device 3 includes the secondary battery 31 of the vehicle.
The secondary battery 31 is mounted on the vehicle and is a
secondary battery used as a drive power source for vehicle travel
or a power source for a large load such as an air-conditioner of
the vehicle. The secondary battery 31 becomes a part of a power
system for a house, when the vehicle parks at a predetermined
position and the vehicle and the charging circuit 4 are connected
by cables 61 through respective connectors. The secondary battery
31 and the charging circuit 4 are disconnected when the vehicle
moves. The secondary battery 31 is connected to the charging
circuit 4 to charge the secondary battery 31 from the charging
circuit 4 or supply power from the secondary battery 31 to the load
device 3 or the power source device 2 through the charging circuit
4. The secondary battery 31 may be referred to as a second
secondary battery. The secondary battery 31 has a relatively large
capacity, so that it may be used as a drive power source for
vehicle travel. The capacity of the secondary battery 31 of the
vehicle may have a capacity, which is larger than that of the
stationary type secondary battery 22. The secondary battery 31 is
connected to the charging circuit 4 only when the vehicle is parked
near a house. The secondary battery 31 is connected to the charging
circuit 4 for a comparatively short period of time. The secondary
battery 31 therefore need be charged rapidly within a short period
of time. The secondary battery 31 can be charged with a
comparatively large charging current during a former period
(initial stage) in its charging period. For example, the charging
speed for the secondary battery 31 is set to be larger than that of
the secondary battery 22. The load device 3 may further include
other loads such as a lighting device or a hot-water supply
device.
The charging circuit 4 is a power conversion circuit, which
converts the power supplied from the power source device 2 and
supplies DC power to the load device 31. The charging circuit 4
also forms the DC power supply apparatus, which supplies the power
source device 2 with the power supplied from the load device 3. The
charging circuit 4 thus forms a multi-input and multi-output power
distribution network, which is connectable to plural power source
devices 2 and plural load devices 3. The charging circuit 4 may be
referred to a power distribution device. The charging circuit 4
includes, as DC power lines, a negative line (N) 41 and a positive
line (P) 42, which respectively provide the negative-side potential
and the positive-side potential. The charging circuit 4 and the
secondary battery 31 are connected through the cables 61 provided
for charging. The cables 61 are shielded wires. The cables 61
electrically connect a casing of the charging circuit 4 and a
chassis of the vehicle, which accommodates the secondary battery 31
to equalize the potentials therebetween.
The charging circuit 4 includes plural converter circuits 43, 44
and 45 provided between the plural power source devices 2 and the
DC power lines. The plural converter circuits 43, 44 and 45 convert
the power supplied from the power source devices 2 and supply the
power to the DC power lines. The converter circuits 43, 44 and 45
also supply the power supplied from the DC power lines to the power
source devices 2. The charging circuit 4 includes plural converter
circuits 51 and 52 provided between the DC power lines and the load
device 3. The plural converter circuits 51 and 52 convert power
supplied from the DC power lines and supply the converted power to
the load device 3. The plural converter circuits 51 and 52 may also
supply power to the DC power lines.
The converter circuit 43 is a full-bridge type step-up and
step-down booster converter circuit (DC/DC). The converter circuit
43 supplies the DC power lines with a voltage, which is stepped up
or down from an output voltage of the solar power generator 21. The
power generation of the solar power generator 21 varies with an
amount of solar radiation. The terminal voltage of the solar power
generator 21 is controlled such that the solar power generator 21
can output maximum power. The converter circuit 43 maintains the DC
inter-line voltage developed between the lines at a fixed level,
even when the voltage of the solar power generator device 21
varies. The DC inter-line voltage is a voltage developed between
the negative line 41 and the positive line 42.
The converter circuit 44 is a full-bridge type step-up and
step-down converter circuit (DC/DC). The converter circuit 44 is a
two-way conversion circuit. The converter circuit 44 supplies the
DC power lines with a voltage, which is stepped up or down from the
terminal voltage of the secondary battery 22. The converter circuit
44 supplies the secondary battery 22 with a voltage, which is
stepped up or down from the voltage of the DC power lines. The
converter circuit 44 is controlled to charge the secondary battery
22 with primarily the power of the commercial power line system 23.
For example, the converter circuit 44 charges the secondary battery
22 with midnight power of the commercial power line system 23. The
converter circuit 44 supplies the power of the secondary battery 22
to the DC power lines and to the load device 3, when no power is
supplied from the commercial power line system 23.
The converter circuit 45 is configured as shown in FIG. 2. The
converter circuit 45 is an AC/DC conversion circuit. The converter
circuit 45 is a two-way conversion circuit. The converter circuit
45 supplies the DC power lines with a voltage, which is stepped up
or down from the AC voltage of the commercial power line system 23
and rectified. The converter circuit 45 supplies the commercial
power line system 23 with a voltage, which is stepped up or down
from the DC power line. The converter circuit 45 includes a
smoothing capacitor C, two reactors L and four switching elements
Q1, Q2, Q3 and Q4 forming a full-bridge circuit FBR. The switching
elements Q1, Q2, Q3 and Q4 may be IGBT elements, for example.
The non-insulating converter circuit 51 is configured as shown in
FIG. 3. The non-insulating converter circuit 51 is a non-insulated
type DC power conversion circuit (NIS-DC/DC), which has no
insulating component, which electrically insulate its input side
and output side. The non-insulating converter circuit 51 has
circuits, which are arranged symmetrically as a two-way step-up and
step-down converter circuit. The non-insulating converter circuit
51 is a step-up/down converter circuit for supplying a voltage,
which is stepped up or down from the voltage of the DC power lines
to charge the secondary battery 31. The non-insulating converter
circuit 51 may include a step-up converter or a step-down
converter. The non-insulating converter circuit 51 includes a
reactor L, half-bridge circuits HBR1 and HBR2, which are provided
at both sides of the reactor L, and smoothing capacitors C1 and C2
provided at both sides. Each of the half-bridge circuits HBR1 and
HBR2 is formed of series-connected two switching elements. The
non-insulating converter circuit 51 supplies a voltage, which is
stepped up or down when the switching elements are
switching-controlled, that is, when controlled to switch over
between ON-state and OFF state.
The casing of the charging circuit 4, which accommodates the
non-insulating converter circuit 51 therein, is grounded. When the
non-insulating converter circuit 51 is connected to the secondary
battery 31 through the cables 61, a stray capacitance STCG is
formed in the charging circuit 4 including the non-insulating
converter circuit 51, for example, between the negative line 41 and
the casing of the non-insulating converter circuit 51. Further, a
stray capacitance STCV is formed in a circuit mounted in the
vehicle including the secondary battery 31, for example, between
the negative line 41 and the casing of the secondary battery 31.
The non-insulating converter circuit 51 does not electrically
insulate an inside of the charging circuit 4 into an input side and
an output side. As a result, the stray capacitances STCG and STCV
form large stray capacitances to the charging circuit 4. If the
commercial power line system 23 and the charging circuit 4 are
electrically connected, leak currents, which flow through the stray
capacitances STCG and STCV, are likely to activate a ground-fault
circuit breaker ELB shown in FIG. 1.
The insulating converter circuit 52 is configured as shown in FIG.
4. The insulating converter circuit 52 is an insulated-type DC
power conversion circuit (ISL-DC/DC). The insulating converter
circuit 52 has circuits, which are arranged symmetrically as a
two-way step-up and step-down converter circuit. The insulating
converter circuit 52 is a step-up/down converter circuit for
supplying a voltage, which is stepped up or down from the voltage
of the DC power lines to charge the secondary battery 31. The
insulating converter circuit 52 may include a step-up converter or
a step-down converter. The insulating converter circuit 52 includes
an insulating transformer (TR) 52a, a first full-bridge circuit
FBR1 connected to a primary coil of the insulating transformer 52a
and a second full-bridge circuit FBR2 connected to a secondary coil
of the insulating transformer 52a. The full-bridge circuit FBR1
supplies an AC current to the primary coil of the insulating
transformer 52a. The full-bridge circuit FBR2 supplies an AC
current to the secondary coil of the insulating transformer 52a. A
smoothing capacitor C1 is provided at a DC side of the full-bridge
circuit FBR1. A smoothing capacitor C2 is provided at a DC side of
the full-bridge circuit FBR2. Each of the full-bridge circuits FBR1
and FBR2 is formed of bridge-connected four switching elements. The
insulating converter circuit 52 supplies a voltage, which is
stepped up or down when the switching elements are
switching-controlled.
The insulating converter circuit 52 includes at both ends thereof a
step-up/down converter circuits SUDC1 and SUDC2. The step-up/down
converter circuit SUDC1 is provided at the DC side of the
full-bridge circuit FBR1. The step-up/down converter circuit SUDC2
is provided at the DC side of the full-bridge circuit FBR2. The
step-up/down converter circuit SUDC1 includes a reactor L1 and a
half-bridge circuit HBR1. The step-up/down converter circuit SUDC1
supplies a voltage, which is stepped up or down when the switching
elements forming the half-bridge circuit HBR1 are
switching-controlled. The step-up/down converter circuit SUDC1 may
be omitted, and instead the converter circuits 43, 44 and 45 may be
configured to perform the function of the step-up/down converter
circuit SUDC1. The step-up/down converter circuit SUDC2 includes a
reactor L2 and a half-bridge circuit HBR2. The step-up/down
converter circuit SUDC2 supplies a voltage, which is stepped up or
down when the switching elements forming the half-bridge circuit
HBR2 are switching-controlled.
The casing of the charging circuit 4 including the insulating
converter circuit 52 therein is grounded. When the insulating
converter circuit 52 is connected to the secondary battery 31, a
stray capacitance STCP is formed in a circuit connected to the
primary side of the insulating transformer 52a. A stray capacitance
STCS is formed in a circuit, which is connected to the secondary
side of the insulating transformer 52a includes the secondary
battery 31. The insulating transformer 52a elctrically insulates
the primary side and the secondary side thereof from each other,
that is, the input side and the output side of the insulating
converter circuit 52. As a result, a current in the primary side is
prevented from directly flowing through the stray capacitance STCS
in the secondary battery 31.
The power conversion efficiency of the non-insulating converter
circuit 51 in case of charging the secondary battery 31 is higher
than that of the insulating converter circuit 52 in case of
charging the secondary battery 31. That is, the non-insulating
converter circuit 51 is configured to exhibit higher power
conversion efficiency than the insulating converter circuit 52
exhibits.
Referring again to FIG. 1, the ground-fault circuit breakers ELB
are provided between the power source devices 2 and the charging
circuit 4.
Filters FLT are provided for the converter circuits 43, 44 and 45
to remove high frequency noises. Fuses F are provided at the low
potential sides between the power source devices 2 and the
converter circuits 43, 44 and 45. Resistors RS are provided for
limiting over-current or conduction testing.
A system relay RLS is provided for the solar power generator 21 and
closed after the solar power generator 21 is connected to the
charging circuit 4. A system relay RLB is provided for the
secondary battery 22 and closed after the secondary battery 22 is
connected to the charging system. A system relay RLG is provided
for the commercial power line system 23 and closed after the
commercial power line system 23 is connected to the charging
circuit 4. The system relay RLG is also a breaker device, which
shuts off electric connection between the commercial power line
system 23 and the charging circuit 4 to disconnect the two. The
system relay RLG may be referred to as a breaker relay 46. The
breaker relay 46 is opened and closed in correspondence to commands
from the control circuit 54.
The breaker relay 46 includes plural relays RLG1, RLG2, RLG3 and
RLG4. The commercial power line system 23 and the charging circuit
4 are connected by closing at least the relays RLG1 and RLG4. The
commercial power line system 23 and the charging circuit 4 are
disconnected from each other by opening all the relays RLG1, RLG2,
RLG3 and RLG4. The breaker relay 46 shuts off power supply from the
commercial power line system 23 to the non-insulating converter
circuit 51, when the charging circuit 4 supplies DC power by the
non-insulating converter circuit 51.
A system relay RLV is provided for the load device 3, that is,
secondary battery 31 of the vehicle, and is closed after the
secondary battery 31 is connected to the charging circuit 4. The
system relay RLV is also a breaker device, which shuts off electric
connection between the secondary battery 31 and the charging
circuit 4 to disconnect the two from each other. The system relay
RLV is also a switching device, which switches over a charging
circuit for the secondary battery 31. The system relay RLV may be
referred to as a switching relay (SW-RL) 53. The switching relay 53
is opened and closed in correspondence to commands from the control
circuit 54. The switching relay 53 includes plural relays (RLV1,
RLV2, RLV3 and RLV4) 53a, 53b, 53c and 53d. The relays 53a, 53b,
53c and 53d are single-throw type. The switching relay 53 is a
switching device, which switches over the charging circuit 4 for
supplying the charging current to the secondary battery 31 to
either a non-insulating circuit including the non-insulating
converter circuit 51 or an insulating circuit including the
insulating converter circuit 52. The charging circuit 4 is capable
of switching the circuit for supplying charging current to the
secondary battery 31 to either the non-insulating converter circuit
51 or the insulating converter circuit 52. The charging circuit 4
is switchable to a state for supplying DC power by the
non-insulating converter circuit 51, in which the input and the
output are not insulated, and to a state for supplying DC power by
the insulating converter circuit 52, in which the input and the
output are insulated by the insulating transformer 52a.
The control circuit in the charging circuit 4 is configured to
control the plural switching elements and the relays provided in
the charging circuit 4 so that circuit elements provided in the
charging circuit 4 perform respective functions. The control
circuit 54 controls switching elements in the converter circuits
43, 44, 45, 51 and 52. The control circuit 54 further controls the
system relays RLS, RLB, RLG and RLB. The charging circuit 4
includes plural sensors, which respectively detect voltages and
currents of the power source devices 2 and voltages and currents of
the load devices 3. Detection signals of these sensors are inputted
to the control circuit 54. The control circuit 54 controls various
circuits provided in the charging circuit 4 in correspondence to
the detection signals of the sensors. The sensors include a voltage
sensor 55 for detecting a voltage V22 of the secondary battery 22
and a current sensor 56 for detecting a charging current Ichr
supplied to the secondary battery 31.
The control circuit 54 includes a microcomputer having a memory
device. The memory device stores computer-readable programs. The
control circuit 54 is programmed to switch over the mode of
operation of the charging circuit 4 to a non-insulating circuit and
an insulating circuit. The non-insulating circuit charges the
secondary battery 31 from the secondary battery 22 with high power
conversion efficiency under a condition that the commercial power
line system 23 and the charging circuit 4 are electrically
disconnected. In the non-insulating circuit, the commercial power
line system 23 and the charging circuit 4 are disconnected so that
only the non-insulating converter circuit 51 operates. That is, in
the non-insulating circuit, power for charging is supplied from the
power source device 2 other than the commercial power line system
23.
The insulating circuit charges the secondary battery 31 from the
commercial power line system 23 while suppressing ground leakage.
In the insulating circuit, the commercial power line system 23 and
the charging circuit 4 are conductively connected so that only the
insulating converter circuit 52 operates. That is, in the
insulating circuit, power for charging is supplied from the power
source device 2 including the commercial power line system 23. The
charging circuit 4 supplies DC power by the non-insulating
converter circuit 51 when a predetermined condition is satisfied.
However it supplies DC power only by the insulating converter
circuit 52 when the predetermined condition is not satisfied. For
example, the predetermined condition may be defined by a threshold,
which separates the former period (initial charging period or
stage) and the latter period (latter charging period or stage) of
charging of the secondary battery 31. It is thus possible in this
case to supply DC power by the non-insulating converter circuit 51
in the former period and then by the insulating converter circuit
52 in the latter period.
The threshold between the former period and the latter period of
charging, may be set as an index, for example, corresponding to
time from the start of charging measured by a timer circuit or
current supplied to charge the secondary battery 31. For example,
the predetermined condition may be set to indicate that the time
from the start of charging is shorter than a predetermined time or
the charging current is larger than a predetermined value. The
predetermined condition may be set to indicate the threshold, which
corresponds to a capacity of power supply of the power source
devices 21 and 22 other than the commercial power line system 23.
In this instance, the DC power may be supplied by the
non-insulating converter circuit 51 and the insulating converter
circuit 52 when the capacity of power supply is high and low,
respectively. The threshold, which indicates the capacity of power
supply, may be set as an index in correspondence to the output
voltage V22 of the power source device 2. For example, the
predetermined condition may be set to correspond that the output
voltage V22 of the power source device 2 is higher than a
predetermined voltage Vth. The switching-over between the
non-insulating circuit and the insulating circuit is performed
based on whether a predetermined switching condition is satisfied.
For example, the control circuit 54 switches the charging circuit 4
to the non-insulating circuit when efficiency is prioritized, and
switches the charging circuit 4 to the insulating circuit when
ground leakage prevention is prioritized. For example, it is
possible to switch over by selecting either one of the
non-insulating circuit and the insulating circuit based on an
instruction of a user. It is further possible to switch over by
selecting either one of the non-insulating circuit and the
insulating circuit based on an application of the charging circuit
4.
Alternatively, the control circuit 54 may automatically switch over
to the non-insulating circuit or the insulating circuit. For
example, the control circuit 54 switches the charging circuit 4 to
the non-insulating circuit in the former period of charging the
secondary battery 31 and to the insulating circuit in the latter
period of charging the secondary battery 31. In another example,
the control circuit 54 switches the charging circuit 4 to the
non-insulating circuit in case that the charging current to the
secondary battery 31 is larger than a predetermined value and to
the insulating circuit in case that the charging current to the
secondary battery 31 is smaller than the predetermined value. In a
further example, the control circuit 54 switches the charging
circuit 4 to the non-insulating circuit in case that the power
source device 2 other than the commercial power line system 23 is
capable of supplying charging power to the secondary battery 31 and
to the insulating circuit in case that the power source device 2
other than the commercial power line system 23 is not capable of
supplying charging power to the secondary battery 31.
For the above-described switching-over operation, the control
circuit 54 is configured to perform control processing shown in
FIG. 5. The control circuit 54 executes switching control
processing repeatedly every predetermined cycle.
At step 171, it is checked whether charging the secondary battery
31 is to be started. This processing is performed by checking
whether the charging circuit 4 and the secondary battery 31 are
connected by the cables 61. At step 172, the breaker relay (RLG) 46
is driven to the OFF state. Thus, the commercial power line system
23 and the charging circuit 4 are electrically disconnected. The
current supply from the commercial power line system 23 to the
charging circuit 4 is shut off. Further, the switching relay
(SW-RL) 53 is driven to the non-insulated (NIS) state to connect
the non-insulating converter circuit 51 and the storage battery 31.
That is, the relays (RLV1, RLV2) 53a, 53b in the first set are
driven to the ON state, and the relays (RLV3, RLV4) 53c, 53d in the
second set are driven to the OFF state. At step 173, the insulating
converter circuit 52, which is disconnected from the secondary
battery 31, is driven to the OFF state and disabled to operate.
That is, the function of the insulating converter circuit 52 is
stopped. Thus, the charging circuit 4 operates as only the
non-insulating circuit. At step 174, the non-insulating circuit
performs charging. That is, the non-insulating converter circuit 51
is controlled to charge the secondary battery 31.
At step 175, it is checked whether a predetermined switching
condition is satisfied. The current supplied in the former period
of charging the secondary battery is generally larger than that
supplied in the latter period of charging the secondary battery.
For example, at step 175, it is checked whether a large current for
the former period of charging is being supplied. At step 175, it
may be checked whether the power source device 2 other than the
commercial power line system 23 is capable of supplying sufficient
power to charge the secondary battery 31. Step 174 is repeated
until the switching condition is satisfied at step 175. Thus, the
charging circuit 4 continues to perform the charging operation by
the non-insulating inverter circuit 51. Step 176 is executed when
the switching condition is satisfied.
At step 176, the breaker relay (RLG) 46 is driven to the ON state.
Thus, the commercial power line system 23 and the charging circuit
4 are electrically connected. The current supply from the
commercial power line system 23 to the charging circuit 4 is
enabled. Further, the switching relay (SW-RL) 53 is driven to the
insulated (ISL) state. That is, the relays (RLV1, RLV2) 53a and 53b
in the first set are driven to the OFF state, and the relays (RLV3,
RLV4) 53c and 53d in the second set are driven to the ON state. At
step 177, the non-insulating converter circuit 51 is driven to the
OFF state and disabled to operate. That is, the function of the
insulating converter circuit 52 is stopped. Thus, the charging
circuit 4 operates as only the insulating circuit. At step 178, the
charging circuit 4 performs charging of the secondary battery 31 by
selecting the insulating converter circuit 52. The insulating
converter circuit 52 is thus controlled to charge the secondary
battery 31.
At step 179, it is checked whether the charging of the secondary
battery 31 has been ended. Step 176 is executed again if the
charging of the secondary battery 31 has not been finished yet.
Thus, the insulating circuit continues to perform the charging
operation. The switching control processing is finished when the
charging of the secondary battery 31 is finished.
As described above, when the charging circuit 4 supplies DC power
by the non-insulating converter circuit 51, the breaker relay 46
shuts off the power supply from the commercial power line system 23
to the non-insulating converter circuit 51 thereby to allow the
power supply to the non-insulating converter circuit 51 from only
the power source devices 21 and 22 other than the commercial power
line system 23. Further, when the charging circuit 4 supplies DC
power by the insulating converter circuit 52, the charging circuit
4 allows the power supply from the commercial power line system 23
to the non-insulating converter circuit 51 thereby to convert the
power supplied from the commercial power line system 23 only by the
converter circuit 51.
In the first embodiment, the voltage V22 of the secondary battery
22 varies as shown in FIG. 6. In the example shown in the figure,
charging is started from time t0. At time t0, the voltage V22 is
Vst. The non-insulating circuit performs charging from time t0 to
time t1. At time t1, the insulating circuit performs charging when
the voltage V22 falls below a threshold voltage Vth at time t1. The
threshold voltage Vth corresponds to the switching condition. The
threshold voltage Vth is the threshold value provided to check
whether the secondary battery 22 is capable of supplying power,
which is sufficient to charge the secondary battery 31.
The charging current Ichr starts to flow from time t0 as shown in
FIG. 7. At time t0, the charging current Ichr is an initial current
Ist. The insulating circuit performs charging from time t0 to time
U. The insulating circuit performs charging when the charging
current Ichr falls below the threshold current Ith at time t1. The
threshold current Ith corresponds to the switching condition. The
threshold current Ith is a threshold value provided to separate the
former period of charging and the latter period of charging. In the
latter period of charging, the secondary battery 31 is supplied
with a latter-period current Ics, which is much smaller than the
initial current Ist.
A switching state of the charging circuit 4 in the first embodiment
is shown in FIG. 8. In the figure, the axis of ordinate indicates
switched state of the switching relay 53. The non-insulating
circuit state (NIS) and the insulating circuit state (ISL) are
provided. Charging is performed from time t0 to time t1 by the
non-insulating converter circuit (NIS-DC/DC) 51. Charging is
performed from time t1 to time t2 by the insulating converter
circuit (ISL-DC/DC) 52.
According to the first embodiment, the power supply from the
commercial power line system 23 to the non-insulating converter
circuit 51 is shut off when the DC power is supplied by the
non-insulating converter circuit 51. The non-insulating converter
circuit 51 therefore receives the power from the power source
devices 21 and 22 other than the commercial power line system 23
and supplies the DC power. The non-insulating converter circuit 51
thus exhibits its higher power conversion efficiency than the
insulating converter circuit 52, which is insulated by the
insulating transformer 52a. As a result, the high power conversion
efficiency can be exhibited in supplying the DC power by the
non-insulating converter circuit 51. Since the commercial power
line system 23 is disconnected, adverse effect of the stray
capacitance at the output side of the non-insulating converter
circuit 51 is minimized.
The power is supplied from only the power source devices 21 and 22
other than the commercial power line system 23 to the
non-insulating converter circuit 51 when the DC power is supplied
by the non-insulating converter circuit 51. The non-insulating
converter circuit 51 therefore can exhibit its high power
conversion efficiency while minimizing adverse effect caused by the
stray capacitance at the output side of the non-insulating
converter circuit 51. The power supplied from the commercial power
line system 23 is converted only by the insulating converter
circuit 52. As a result, adverse effect of the stray capacitance at
the output side of the insulating converter circuit 52 is
minimized.
The commercial power line system 23 and the charging circuit 4 are
disconnected by the breaker relay 46 when the secondary battery 31
is charged through the non-insulating converter circuit 51. As a
result, the power supplied by the commercial power line system 23
is prevented from leaking to ground through the stray capacitance
STCV formed in the vehicle. The power can be supplied through the
non-insulating converter circuit 51, in which no insulating
transformer is provided. As a result, the power conversion
efficiency can be improved than in a case, in which the power is
supplied through only the insulating converter circuit 52 having
the insulating transformer 52a.
The non-insulating converter circuit 51 or the insulating converter
circuit 52 can be selected so that the charging circuit 4 is
switched to operate as the non-inverting circuit or the inverting
circuit based on whether the predetermined switching condition is
satisfied. If the predetermined switching condition is not
satisfied, the DC power is supplied only by the insulating
converter circuit 52 and hence the commercial power line system 23
can be insulated from the load device 3.
High power conversion efficiency is used by the non-insulating
converter circuit 51 in the former period of charging of the
secondary battery 31. Further, adverse effect caused by the stray
capacitance is avoided by the insulating converter circuit 52. The
threshold condition for dividing the charging period into the
former period and the latter period may be set by the index, which
indicates the time measured by the timer device from the start of
charging or the charging current to the secondary battery. For
example, the predetermined condition may be set to correspond to
that the time measured from the start of charging is shorter than
the predetermined time or the charging current is larger than the
predetermined value.
High power conversion efficiency of the non-insulating converter
circuit 51 is used when the power supply capability of the power
source devices 21 and 22 other than the commercial power line
system 23 is high. In addition, the adverse effect caused by the
stray capacitance is reduced by the insulating converter circuit 52
when the power supply capability of the power source devices 21 and
22 other than the commercial power line system 23 is low. The
threshold for indicating the capability of power supply may be set
based on the output voltage V22 of the power source device 22 as
the index. For example, the predetermined condition may be set to
correspond to that the output voltage of the power source device 22
is higher than the predetermined voltage. Alternatively, the
threshold may be set based on the state of charge (SOC) of the
storage battery, which is determined by integration of the charging
and discharging current or by coulomb counting method.
The charging power is supplied through the non-insulating converter
circuit 51 when the charging current flowing to the secondary
battery 31 is large. The charging power is supplied only through
the insulating converter circuit 52 when the charging current
flowing to the secondary battery 31 is reduced. As a result, a
large charging current can be supplied with high efficiency. The
conversion efficiency of entire power needed for charging can be
enhanced efficiently. While the charging current is small, the
advantage of the insulating converter circuit 52 can be utilized.
For example, when the secondary battery 31 is charged only through
the insulating converter circuit 52, the primary side and the
secondary side of the insulating transformer 52a is insulated by
separation. As a result, the power of the commercial power line
system 23 is prevented from ground leakage of current through the
stray capacitance STCS.
The non-insulating converter circuit 51 and the insulating
converter circuit 52 are provided as separate circuits in the
charging circuit 4. These circuits are connected selectively to the
load device 3.
Second Embodiment
In a DC power supply apparatus according to a second embodiment, as
shown in FIG. 9, a charging circuit (conversion circuit) 204 is
configured to charge secondary batteries 31 and 231 of two vehicles
at the same time. The charging circuit 204 includes first cables 61
and second cables 261.
A switching relay (SW-RL) 253 includes single-throw double-pole
relays (RLV1, RLV2, RLV3 and RLV4) 253a, 253b, 253c and 253d, which
form the system relay RLV. The relays 253a, 253b, 253c and 253d
connect the non-insulating converter circuit 51 and the insulating
converter circuit 52 switchably to the first cables 61 and the
second cables 261. The relays 253a, 253b, 253c and 253d connect the
insulating converter circuit 52 and the second cables 261 when the
insulating converter circuit 52 is connected to the first cables
61. The relays 253a, 253b, 253c and 253d connect the non-insulating
converter circuit 51 and the second cables 261 when the insulating
converter circuit 52 is connected to the first cables 61.
The charging circuit 204 includes a breaker relay (RLW) 246 as a
separating device for separating charging circuits 45, 46 and 52
including the commercial power line system 23 from the charging
circuits 43, 44 and 51 including only the power source device 2
other than the commercial power line system 23. The breaker relay
246 includes a breaker relay (RLW1) 246a and a breaker relay (RLW2)
246b. The breaker relay 246a is provided in the negative line 41 to
connect and disconnect the negative line 41. The breaker relay 246b
is provided in the positive line 42 to connect and disconnect the
negative line 41. The breaker relays 246a and 246b charge the
secondary battery 31 by the non-insulating converter circuit 51 and
are driven to the OFF-state when the secondary battery 331 is
charged by the insulating converter circuit 52. The breaker relays
246a and 246b are driven to the ON state when the power of the
commercial power line system 23 is charged to the secondary battery
22 and 31. The breaker relays 246a and 246b are driven to the ON
state when power of the power source devices 2 other than the
commercial power line system 23 is supplied to the battery 231. The
breaker relays 246a and 246b are also driven to the ON state when
the power of the secondary power source devices 31 is supplied to
the secondary battery 231. The breaker relays 246a and 246b form a
breaker device for shutting off the power supply from the
commercial power line system 23 to the non-insulating converter
circuit 51.
A control circuit 254 is configured to perform charging processing
for only one of the secondary battery 31 and the secondary battery
231 by controlling the switching relay 253 in the similar way as in
the first embodiment. The control circuit 254 drives the breaker
relays 246a and 246b to the ON states.
The control circuit 254 performs processing of charging the two
batteries 31 and 231 at the same time. The control circuit 254
charges the secondary battery 31 only through the non-insulating
converter circuit 51 and at the same charges the secondary battery
331 only through the insulating converter circuit 52. The control
circuit 54 charges the secondary battery 31 only through the
insulating converter circuit 52 and at the same charges the
secondary battery 331 only through the non-insulating converter
circuit 51. The control circuit 254 drives the breaker relays 246a
and 246b to the OFF states when both of the second batteries 31 and
231 are charged at the same time. The breaker relays 246a and 246b
thus disconnect the charging circuit including the non-insulating
converter circuit 51 from the commercial power line system 23. When
the charging circuit 204 supplies the DC power by the
non-insulating converter circuit 51, the breaker relay 246 operates
as a breaker device, which shuts off power supply from the
commercial power line system 23 to the non-insulating converter
circuit 51. As a result, adverse effect, which the stray
capacitance of the circuit including the secondary battery 31
influences the commercial power line system 23 is reduced. The
circuit including the secondary battery 331 is separated from the
commercial power line system 23 by the insulating converter circuit
52. As a result, the influence of the stray capacitance of the
circuit including the secondary battery 231 is reduced.
According to the second embodiment, the charging circuit 204
includes the non-insulating converter circuit 51 and the insulating
converter circuit 52 as independent circuits. The switching relay
253 forms a switching device, which connect either one of the
non-insulating converter circuit 51 and the insulating converter
circuit 52 selectively to the load device 3. The switching device
253 connects the non-insulating converter circuit 51 and the
insulating converter circuit 52 to the plural load devices 31 and
231 switchably.
The DC power can be supplied to the plural load devices 31 and 231
by the non-insulating converter circuit 51 and the insulating
converter circuit 52.
Third Embodiment
In a DC power supply apparatus according to a third embodiment, as
shown in FIG. 10, a charging circuit (conversion circuit) 304
includes a switchable converter circuit 351 in place of the
non-insulating converter circuit 51 and the insulating converter
circuit 52, which are provided in the first and the second
embodiments. The switchable converter circuit 351 is selectively
switchable to a non-insulating circuit and an insulating circuit.
The switchable converter circuit 351 is a switchable DC power
conversion circuit (NIS-ISL-DC/DC). The switchable converter
circuit 351 includes a part, which is provided as the insulating
converter circuit, and a switching relay (SW-RL) 353, which is
provided as a switching device. The system relay RLV includes two
relays RLV1 and RLV2. A control circuit 354 controls the breaker
relay 46 to disconnect the commercial power line system 23 from the
charging circuit 304 and also controls the switching relay 353 to
switch over the switchable converter circuit 351 to either one of
the non-insulating circuit and the insulating circuit.
The switchable converter circuit 351 is configured as shown in FIG.
11. The switchable converter circuit 351 includes circuits, which
are provided symmetrically as a two-way step-up/down converter
circuit. The switchable converter circuit 351 is a step-up/down
converter circuit, which supplies a voltage stepped up or stepped
down from the voltage of the power lines to charge the secondary
battery 31. The switchable converter circuit 351 may alternatively
be formed of only a step-up converter circuit or a step-down
converter circuit. The switchable converter circuit 351 includes an
insulating transformer (TR) 351a, a first full-bridge circuit FBR1
provided at the primary side of the insulating transformer 351a and
a second full-bridge circuit FBR2 provided at the secondary side of
the insulating transformer 351a.
The full-bridge circuit FBR1 supplies an AC current to the primary
coil of the insulating transformer 351a. The full-bridge circuit
FBR2 supplies an AC current to the secondary coil of the insulating
transformer 351a. A smoothing capacitor C1 is provided at a DC side
of the full-bridge circuit FBR1. A smoothing capacitor C2 is
provided at a DC side of the full-bridge circuit FBR2. Each of the
full-bridge circuits FBR1 and FBR2 is formed of bridge-connected
four switching elements.
In case that the switchable converter circuit 351 is the insulating
circuit, plural switching elements of one of the full-bridge
circuits FBR1 and FBR2, which is provided at the input side, are
switching-controlled to convert the DC power to the AC power and
supply the AC power to the insulating transformer 351a. The AC
power is voltage-converted by the insulating transformer 351a.
Further, plural switching elements of the other of the full-bridge
circuits FBR1 and FBR2, which is provided at the output side, are
switching-controlled to convert the AC power to the DC power and
output the DC power. In case that the switchable converter circuit
351 is the non-insulating circuit, the plural switching elements of
the full-bridge circuits FBR1 and FBR2 are switching-controlled to
perform voltage conversion by the step-up/down converter circuit
formed by the full-bridge circuits FRB1, FRB2 and the insulating
transformer 351a.
The switchable converter circuit 351 includes the switching relay
353 as a switching device, which switches over the circuit 353 to
either the insulating circuit or the non-insulating circuit. The
switching relay 353 includes the relay (RLT1) 353a, which is
capable of connecting and disconnecting the winding start end of
the primary coil of the insulating transformer 351a and the winding
start end of the secondary coil of the insulating transformer 351a.
The relay 351 includes the relay (RLT) 353b, which is capable of
connecting and disconnecting ground lines of the full-bridge
circuits FBR1 and FBR2. When the relay 353 is open, that is, both
of the relays 353a and 353b are open, the primary side terminal and
the secondary side terminal of the insulating transformer 351a are
disconnected and the ground lines of the full-bridge circuits FBR1
and the FBR2 are also disconnected. In this instance, the
insulating transformer 351a is capable of operating as a normal
insulating transformer. That is, when the switching relay 353 is
open, the insulating circuit, which is insulated by the insulating
transformer 351, is formed. When the relay 353 is closed, that is,
both of the relays 353a and 353b are closed, the primary side
terminal and the secondary side terminal of the insulating
transformer 351a are shorted and the ground lines of the
full-bridge circuits FBR1 and the FBR2 are connected. That is, when
the switching relay 353 is closed, the non-insulating circuit,
which is not electromagnetically-coupled by the insulating
transformer 351, is formed.
The relay 353 is arranged so that leak inductances Lk1 and Lk2 are
provided in series between the full-bridge circuit FBR1 and the
full-bridge circuit FBR2 with the relays 353a and 353b being
closed. With the switching relay 353 being closed, the leak
inductances Lk1, Lk2 and the switching arms of the full-bridge
circuits FBR1, FBR2 connected to the leak inductances Lk1, Lk2 form
the non-insulating converter circuit, which includes a step-down
chopper circuit and a step-up chopper circuit. For example, when
the secondary battery 31 is charged from the secondary battery 22,
the leak inductances Lk1, Lk2 and one switching arm of the
full-bridge circuit FBR1 connected to the leak inductances Lk1, Lk2
form the step-down chopper circuit. In this case, the leak
inductances Lk1, Lk2 and one switching arm of the full-bridge
circuit FBR2 connected to the leak inductances Lk1, Lk2 form the
step-up chopper circuit.
The switchable converter circuit 351 includes at its both ends
step-up/down converter circuit SUDC1 and SUDC2. The step-up/down
converter circuit SUDC1 is provided at the DC side of the
full-bridge circuit FBR1. The step-up/down converter circuit SUDC2
is provided at the DC side of the full-bridge circuit FBR2. The
step-up/down converter circuit SUDC1 includes a reactor L1 and the
half-bridge circuit HBR1. The step-up/down converter circuit SUDC1
supplies a voltage stepped up or stepped down, when switching
elements of the half-bridge circuit HBR1 are switching-controlled.
It is possible to provide this function by the converter circuits
43, 44 and 45 without providing the step-up/down converter circuit
SUDC1. The step-up/down converter circuit SUDC2 includes a reactor
L2 and the half-bridge circuit HBR2. The step-up/down converter
circuit SUDC2 supplies a voltage stepped up or stepped down, when
switching elements of the half-bridge circuit HBR2 are
switching-controlled.
According to the third embodiment, a turn ratio of the primary coil
and the secondary coil of the insulating transformer 351a is 1
(1:1). The insulating transformer 351a and the full-bridge circuits
FBR1, RBR2 form a step-down type insulating converter circuit. The
step-down type insulating converter circuit, which is formed of the
insulating transformer 351a and the full-bridge circuits FBR1,
FBR2, and the circuits SUD1, SUDC2 performs conversion between the
voltage of the DC power lines and the voltage of the secondary
battery 31.
A casing of the charging circuit 304 including the switchable
converter circuit 351 is grounded. When the switchable converter
circuit 351 is connected to the secondary battery 31, a stray
capacitance STCP is formed in a circuit connected to the primary
side of the insulating transformer 351a. A stray capacitance STCS
is formed in a circuit including the battery 3 and connected to the
secondary side of the insulating transformer 351. Since the
insulating transformer 351a insulates its primary side and
secondary side, the current in the primary side is prevented from
directly flowing through the stray capacitance STCS.
The efficiency of power conversion of the non-insulating circuit in
charging the secondary battery 31 is higher than that of the
insulating circuit in charging the secondary battery 31. That is,
the switchable converter circuit 351 is configured to exhibit the
higher power conversion efficiency by the non-insulating circuit
than by the insulating circuit.
The control circuit 354 in the charging circuit 304 is configured
to perform switching control processing shown in FIG. 12. The
control circuit 354 executes the processing repeatedly every
predetermined cycle.
At step 171, it is checked whether charging the secondary battery
31 is to be started. At step 372, the breaker relay (RLG) 46 is
driven to the OFF state. Further, the switching relay 353 is driven
to the non-insulated (NIS) state. That is, the relays (RLT1, RLT2)
353a, 353b are driven to the ON state. Thus, the primary side and
the secondary side of the insulating transformer 351a are shorted.
As a result, the charging circuit 4 operates as only the
non-insulating circuit. At step 374, the non-insulating circuit
performs charging. That is, the non-insulating circuit formed by
the switchable converter circuit 351 is controlled to charge the
secondary battery 31. Here, the control circuit 354 controls the
step-up/down converter circuit SUDC1 so that the stepped-up voltage
is supplied to the full-bridge circuit FBR1 from the voltage of the
DC power lines, that is, the voltage of the secondary battery 22.
The control circuit 354 controls the plural switching elements of
the full-bridge circuits FBR1 and FBR2 so that the leak inductances
Lk1, Lk2 and the switching arms of the full-bridge circuits FBR1,
FBR2 connected to the leak inductances Lk1, Lk2 operate as the
non-insulating converter circuit. The control circuit 354 further
controls the step-up/down converter circuit SUDC2 so that the DC
voltage supplied from the full-bridge circuit FBR2 is supplied
after conversion to a voltage suitable for charging the secondary
battery 31.
At step 175, it is checked whether a predetermined switching
condition is satisfied. Step 374 is repeated until the switching
condition is satisfied at step 175. Thus, the non-insulating
circuit continues to perform the charging operation. Step 376 is
executed when the switching condition is satisfied.
At step 376, the breaker relay (RLG) 46 is driven to the ON state.
Further, the switching relay (SW-RL) 353 is driven to the insulated
(ISL) state. That is, the relays (RLT1, RLT2) 353a, 353b are driven
to the OFF state. Thus, the charging circuit 4 operates as only the
insulating circuit. At step 378, the insulating circuit performs
charging. That is, the insulating circuit formed by the switchable
converter circuit 351 is controlled to charge the secondary battery
31. Here, the control circuit 354 controls the step-up/down
converter circuit SUDC1 so that the stepped-up voltage is supplied
from the voltage of the DC power lines, that is, from the voltage
of the secondary battery 22. The control circuit 354 controls the
full-bridge circuit FBR1 by phase-shift PWM method so that a
zero-volt switching (ZVS) is performed. In the phase-shift PWM
control method, the plural switching elements of the full-bridge
circuit FBR1 are turned on and off at a duty ratio of 50%. The
phase-shift PWM control method controls a shift time between two
switching timings, that is, one switching timing of a pair of
switching elements which supplies current to the primary coil of
the insulating transformer 351a in the forward direction and the
other switching timing of a pair of switching elements which
supplies current to the primary coil of the insulating transformer
351a in the reverse direction. Thus, the forward current supply
period and the reverse current supply period are controlled. In
this instance, the voltage resonates due to an inductive component
of the insulating transformer 351a including the leak inductances
Lk1, Lk2 and a capacitive component including capacitors formed in
parallel to the plural switching elements.
When the voltage between both terminals of the switching element
becomes zero due to resonance, the switching element is
switching-controlled. For example, when the terminal voltage
becomes zero, the switching element is controlled from the OFF
state to the ON state. By the ZVS operation, a crossing time of
current and voltage at the switching edge is reduced and hence
switching loss is reduced. When power is supplied from the
full-bridge circuit FBR1 to the full-bridge circuit FBR2, resonance
caused by the leak inductance Lk1 and the capacitor of the
switching element of the full-bridge circuit FBR1 is used. When
power is supplied from the full-bridge circuit FBR2 to the
full-bridge circuit FBR1, resonance caused by the leak inductance
Lk2 and the capacitance of the switching element of the full-bridge
circuit FBR2 is used. The control circuit 354 controls the
full-bridge circuit FBR2 so that the AC power supplied from the
insulating transformer 351a is converted to the DC power and the DC
power is supplied to the step-up/down converter circuit SUDC2. The
control circuit 354 also controls the step-up/down converter
circuit SUDC2 so that the DC power supplied from the full-bridge
circuit FBR2 is converted to the voltage suitable for charging the
secondary battery 31 and the voltage is supplied.
At step 179, it is checked whether the charging of the secondary
battery 31 has been ended. Step 376 is executed again if the
charging of the secondary battery 31 has not been finished yet.
Thus, the insulating circuit continues to perform the charging
operation. The switching control processing 370 is finished when
the charging of the secondary battery 31 is finished.
According to the third embodiment, the switching device 353 is
provided to close or open the primary terminal and the secondary
terminal of the insulating transformer 351a and to close or open
the negative-side potential line of the first full-bridge circuit
FBR1 and the negative potential line of the second full-bridge
circuit FBR2. The switchable converter circuit 351 is provided to
switch over to the non-insulating converter circuit or to the
insulating converter circuit in correspondence to closing or
opening of the switching device 353. Thus, the switchable converter
circuit 351 forms the insulating converter circuit and the
non-insulating converter circuit.
The non-insulating converter circuit and the insulating converter
circuit can be provided by using the switching elements of the
first full-bridge circuit FRB1 and the second full-bridge circuit
FRB2. The non-insulating converter circuit is a step-up converter
circuit formed by the first bridge circuit FBR1, the second
full-bridge circuit FBR2 and the inductive components Lk1, Lk2 of
the insulating transformer 351a, which is formed when the switching
device 353 is in the shorted state. As a result, the step-up/down
converter circuit, which operates as the non-insulating converter
circuit, can be provided by the inductive component of the
insulating transformer 351a provided when the switching device 353
is in the shorted state.
Fourth Embodiment
In a DC power supply apparatus according to a fourth embodiment, as
shown in FIG. 13, a charging circuit (conversion circuit) 404 is
configured to include a switchable DC power converter circuit 451.
The switchable converter circuit 451, which is switchable
selectively to a non-insulating circuit and an insulating circuit.
The converter circuit 451 includes an insulating transformer 451a,
which insulates the primary side and the secondary side. The turn
ratio of the primary coil and the secondary coil of the insulating
transformer 451a is n (1:n, n>1). The insulating transformer
451a converts the voltage supplied from the full-bridge circuit
FBR1 by multiple-folds (n) and supplies it to the full-bridge
circuit FBR2. As a result, the insulating transformer 451a and the
full-bridge circuits FBR1, FBR2 form a step-up type insulating
converter circuit.
According to the fourth embodiment, only the step-up/down converter
circuit SUDC2 is provided. When the secondary battery 31 is
charged, the voltage of the DC power lines is stepped up by the
insulating transformer 451a and then regulated by the step-up/down
converter circuit SUDC2 to a voltage suitable for charging the
secondary battery 31. When power is supplied from the secondary
battery 31 to the DC power lines in reverse, the voltage is stepped
up by the step-up/down converter circuit SUDC2, and then stepped
down by the insulating transformer 451a to a fraction of multiple
(1/n) and supplied to the DC power lines.
According to the fourth embodiment, not only the insulating
function but also the transforming function of the insulating
transformer 451a can be utilized.
Other Embodiments
Although the DC power supply apparatus is described with reference
to the preferred embodiments, it may be implemented in other
modified forms.
For example, in the embodiments described above, only the
non-insulating converter circuit 51 is activated and rendered
operable in the non-insulating circuit. Instead, the insulating
converter circuit 52 may as well be activated and rendered operable
in the non-insulating circuit. As a result, the charging current to
the secondary battery 31 can be increased. In such a modification,
only the insulating converter circuit 52 is activated and rendered
operable in the insulating circuit. Thus, in the non-insulating
circuit, power conversion efficiency can be improved by
additionally using the non-insulating converter circuit 51.
Further, in the insulating circuit, advantage of using the
insulating converter circuit 52 can be provided.
For example, the switching device and the breaker device are formed
by relays in the embodiments described above. Alternatively, the
switching device and the breaker device may be formed by
semiconductor switches.
For example, structure and function provided by the control circuit
may be provided by only software, hardware or combination of
software and hardware. The control circuit may be formed as an
analog circuit.
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